Layout Engineer (Industrial Engineering / Factory Site Design)
Location: Boston, MA
Role Overview:
The Layout Engineer will be responsible for end-to-end site and factory layout management, including building-level and campus-level planning. This role focuses on designing, optimizing, and scaling manufacturing facilities by integrating production systems, material flow, warehouse operations, and site infrastructure into a cohesive and efficient layout. The ideal candidate will combine industrial engineering expertise, data-driven analysis, and cross-functional leadership to support large-scale manufacturing growth.
Key Responsibilities:- Lead factory layout design across manufacturing lines, warehouse/storage areas, material flow, people flow, and ancillary/support spaces
- Develop long-term site master plans to support phased capacity expansion and future scalability
- Define and implement layout governance and standards, including change management, visual factory standards, drafting standards, and layout processes
- Create and maintain block layouts and detailed 2D/3D layouts aligned with Plan of Record (POR) and business requirements
- Design and optimize end-to-end material flow, including inbound, internal logistics (WIP), and outbound finished goods flow
- Own and manage overall site layout, including building placement, external logistics flow (truck movement, dock doors, yards), utilities, and infrastructure planning
- Optimize dock utilization, yard flow, and transportation interfaces to improve logistics efficiency at the site level
- Collaborate with cross-functional teams (Manufacturing, Operations, Supply Chain, Facilities, Construction, EHS) to align on layout requirements and ensure seamless execution
- Perform data-driven analysis to optimize space utilization, flow efficiency, labor productivity, and cost
- Develop and integrate PFEP (Plan for Every Part) into layout decisions, including storage strategy, packaging, and line-side delivery
- Define and track layout performance metrics, including flow distance, aisle utilization, space density, throughput, and bottlenecks
- Support capacity planning and modeling using OEE, cycle time analysis, and throughput simulations
- Drive factory densification initiatives by eliminating non-value-added movement and improving layout efficiency
- Translate complex layout and operational data into clear, executive-level insights to support strategic decisions
Basic Qualifications:- Bachelor's degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or related field 7+ years of experience in site/factory layout planning, industrial engineering, or manufacturing systems
- Experience in large-scale manufacturing environments (e.g., automotive, battery, energy, or heavy industry)
- Strong understanding of site planning, material flow, and facility design principles
Preferred Qualifications:- Experience in greenfield site development and large-scale factory ramp-upProven experience in site master planning, including yard design, dock strategy, and infrastructure planning
- Hands-on experience with PFEP, warehouse design, and material handling systems (AGVs, AMRs, conveyors)
- Proficiency in layout tools such as AutoCAD, Revit, or similar 2D/3D design software
- Experience with simulation tools (e.g., FlexSim) for factory and logistics modeling
- Strong knowledge of Capacity Model and Labor industrial engineering methodologies (OEE, line balancing, takt time, cycle time analysis)
- Experience working with construction and facilities teams on site execution and infrastructure integration
- Familiarity with safety, environmental, and regulatory considerations in site design
Key Skills Competencies:- Strong analytical and data-driven decision-making skills
- Ability to manage complex, cross-functional projects across site and factory levels
- Excellent communication skills with the ability to influence stakeholders from shop floor to executive leadership
- Systems-thinking mindset with attention to detail
- Proven ability to manage multiple priorities in a fast-paced, high-growth environment
